Method of producing a multi-layered printed absorbent article

ABSTRACT

A method for producing a multi-layered absorbent article. At least two of the layers include a colored region.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of application Ser. No.12/548,603 now U.S. Pat. No. 8,262,633 and Ser. No. 12/548,604 now U.S.Pat. No. 8,292,864 both of which were filed on 27 Aug. 2009. ApplicationSer. No. 12/548,603 is a continuation-in-part of application Ser. No.12/188,543 now U.S. Pat. No. 7,967,801 and Ser. No. 12/188,598 now U.S.Pat. No. 8,058,501 both of which were filed on 8 Aug. 2008. ApplicationSer. No. 12/548,604 is a continuation-in-part of application Ser. No.12/188,543 and Ser. No. 12/188,598 both of which were filed on 8 Aug.2008.

FIELD OF THE INVENTION

Disclosed is a method for producing an absorbent article having multiplelayers.

BACKGROUND OF THE INVENTION

Absorbent articles having colored regions are preferred by consumers forthe benefits they provide. One benefit is that colored regions can helpmask bodily fluid, for instance menses or urine, collected by theabsorbent article. The ability to mask the absorbed bodily fluidsprovides a user with an increased feeling of cleanliness and protectionfrom soiled undergarments. Another benefit is that colored regions insecondary layers, especially in the central region of the absorbentarticle where bodily fluid is primarily absorbed, provide a desiredvisual impression of depth to a user. This perception of absorbentarticle depth increases a user's confidence in the absorption capacityof the absorbent article, resulting in increased confidence that bodilyfluids will be successfully absorbed and stored; thereby reducing thechance of soiled undergarments.

However it has been difficult to produce absorbent articles having thedesired colored regions. One of the difficulties has been providing thecentral region of an absorbent article with a colored region that willprovide the desired coverage; as some users associate stain patternsthat extend outside the central colored region as indicating that theabsorbent capacity of the absorbent article is exhausted. In someabsorbent articles, the central colored region could account for lessthan 25% of the absorbent capacity of the absorbent article. Mostdigital printers lack the width-wise spray area to provide the desiredcolored region width to the central region, especially if products areproduced multi-lane or broad front, where two or more products aresimultaneously on the production line. One attempted fix has been to tryand arrange multiple digital printers in a side-by-side arrangement toprovide increased spray area in the widthwise direction of the absorbentarticle. The rearrangement of the digital printers has not provided thedesired results. The side-by-side arrangement increases the cost of thedigital printers and further decreases the reliability of the printingprocess. If one of the coupled printheads in the width direction fails,the production line stops. Image quality is also at risk as the multipledigital printers must be coordinated to produce a colored region that isnot noticeably offset in the machine direction. As the colored region ison or close to the absorbent article surface any errors are quicklynoticed by a user, reducing or eliminating the benefits provided bycolored regions.

Another attempt to provide colored regions having the desired coveragearea has been to use a contact method of printing, such as flexographicprinting. Contact printing has traditionally been an economical way toprint large or wide patterns on an absorbent article with reproducibleresults. However, contact printing may result in higher initial expensebecause the specific pattern rolls, plates, or screens must bemanufactured. Because of the custom manufacturing, subsequent changes tothe print pattern may require the manufacture of new equipment and maylimit the economic feasibility of quickly changing the print pattern forspecific needs or limited production situations. A further issue is thatcontact printing does not work equally well with all substrates. Forexample, to create the visual perception of depth the central portionwill be printed on to create a central colored region. However to createthe visual perception of depth, a layer below the surface layer (toplayer) is printed to produce the central colored region. In general thelayers below the surface layer include “dusty” or “loose” non-woven orcellulose containing web materials that cannot be printed on using acontact method, as the loose fiber sticks to the print plate resultingin light or missing print.

In a further effort to provide the desired colored regions to anabsorbent article, multiple printing processes have been used during theproduction of an absorbent article. These multiple printing processeshave several shortcomings. In one method a single layer is printed onmultiple times. However, printing on a single layer of an absorbentarticle multiple times does not provide a perception of depth thatprinting on multiple layers does. Another method involves printing onmultiple layers of an absorbent article after they have been brought incontact with one another. This reduces the surfaces which can beprinted, restricting printed webs to being in contact with one another,thus the perception of depth is lost. An additional method usespreprinted rolls of materials to produce absorbent articles. However theuse of preprinted rolls increases the cost of the absorbent articles dueto supply chain complexity and increased product scrap linked toregistration of the image(s) in the preprinted roll.

Therefore there is a need for a method of producing absorbent articleshaving colored regions on multiple layers, such that the colored regionsprovide a visual perception of depth and sufficient coverage to at leastpartially mask absorbed bodily fluids.

SUMMARY OF THE INVENTION

A method of producing a multi-layered absorbent article having two ormore colored regions is provided. The method comprises the steps ofproviding an absorbent article converting line; supplying a firstsubstrate to the converting line; printing a first colored region to thefirst substrate using contact printing at a contact printing station;supplying a second substrate to the converting line; printing a secondcolored region to the second substrate using non-contact printing at anon-contact printing station; and combining the first substrate having afirst colored region with the second substrate having a second coloredregion to produce an absorbent article.

A method of producing a multi-layered absorbent article having two ormore colored regions is provided. The method comprises the steps ofproviding an absorbent article converting line; supplying a film web tothe converting line; printing a first colored region to the film webusing contact printing at a contact printing station; supplying anon-woven web material; printing a second colored region to thenon-woven web material using non-contact printing at a non-contactprinting station; cutting the film web into individual sheets; cuttingthe non-woven web material into individual sheets; and combining anindividual sheet of film and an individual sheet of non-woven materialto produce an absorbent article.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of one embodiment of the presentinvention.

FIG. 2 is a schematic representation of a flexographic printing processof the present invention.

FIG. 3 is a schematic representation of a gravure printing process ofthe present invention.

FIG. 4 is a schematic of an absorbent article.

FIG. 5 is a cross-section of the absorbent article illustrated in FIG.4.

FIG. 6 is a schematic of the second substrate of the absorbent articleof FIG. 4.

FIG. 7 is a schematic of the first substrate of the absorbent article ofFIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a method of producing a printedmulti-layered absorbent article on a converting line. A first substrate,such as a topsheet, is supplied to a converting line and printed with afirst colored region using a contact method of printing, for instance,flexographic printing, rotogravure printing, offset printing,lithographic printing, screen printing, or the like. A second substrate,such as a non-woven or cellulose based secondary topsheet is alsosupplied to the converting line and printed with a second colored regionusing a non-contact method of printing, such as, for example, wax jetprinting, ink jet printing, bubble jet printing, laser jet printing, orthe like. Following the printing steps the first substrate and secondsubstrate are combined in the process of producing an absorbent article,such as a feminine sanitary napkin.

As used herein the term “converting line” means a manufacturing lineused to make absorbent articles. The purpose of a converting line is totake raw materials, process and combine them to produce absorbentarticles. A converting line comprises various unit-operations used inthe production of absorbent articles. A unit-operation can range fromsimple actions such as raw material transport (unwind, meter,reposition, and the like) to complex material transformations (melting,cutting, stretching, fluid application (ink, lotion, adhesive), and thelike). In the converting line many unit-operations are occurring inparallel as well as in sequence to produce an absorbent article.

As used herein, the term “print” or “printing” means to produce acolored region on a substrate. Frequently, printing involves formationof a colored region by the transfer of pigment, colorant, or brightenerin the form of ink, wax, paint, or the like to a substrate. The printedcolored region is visible to the human eye and can include, for example,shapes, patterns, designs, objects, likenesses of real or fictitiouscharacters, or the like, or combinations thereof. Examples of printingmethods include contact printing and non-contact printing. Contactprinting includes the direct transfer of pigment from a print roll,plate, or screen to a substrate. In non-contact printing methods, theprinting apparatus does not directly contact the substrate, for examplewhen printing from ink jet printers, wax jet printers, bubble jetprinters, laser jet printers, or the like, or combinations thereof.

As used herein, the term “substrate” means a web of material capable ofmoving through a converting line. A substrate can include contiguousmaterial wherein individual units of material are connected or directlyjoined to the immediately preceding and trailing units of material. Forexample, a substrate may include a continuous web of woven material,nonwoven material, film, or the like, or combinations thereof. Asubstrate may also include interconnected absorbent articles in variousstages of manufacture. A substrate may also include a web of discreteunits of material separated by space or by other materials. For example,a substrate may include discreet absorbent articles moving through aconverting line via one or more conveyor belts or other means ofconveyance known in the art.

As used herein, the phrase “absorbent article” refers to devices whichabsorb and contain fluids, which includes bodily fluids, and morespecifically refers to devices which may be placed against or near theskin to absorb and contain the various fluids discharged from the body.In typical use absorbent articles are not intended to be laundered orotherwise restored or reused after a single use. Examples of absorbentarticles include, but are not limited to sanitary tissue products, forexample facial tissue, toilet tissue, paper towels, wipes; home careproducts, for example cleaning wipes, such as Swiffer® (The Procter &Gamble Company, Cinc., Ohio); beauty care products such as wipes andcleaning pads; feminine hygiene products, for example sanitary napkins,pantiliners, tampons, interlabial devices and the like; infant diapers;children's training pants; adult incontinence products. Non-limitingexamples of pantiliners and sanitary napkins which may be provided witha first colored region on a laminate substrate and second colored regionon a lower substrate include those manufactured by The Procter & GambleCompany of Cincinnati, Ohio, such as ALWAYS ULTRA, ALWAYS INFINITY, andALWAYS pantiliners. Absorbent articles such as those disclosed in U.S.Pat. Nos. 4,324,246, 4,463,045, 6,004,893, 4,342,314, 4,463,045,4,556,146, 4,589,876, 4,687,478, 4,950,264, 5,009,653, 5,267,992, andRe. 32,649 are also contemplated as being absorbent articles that mightbenefit from a first and second colored region.

Absorbent articles, and their individual components, such as a liquidpervious topsheet, a secondary topsheet, an absorbent core, and asubstantially liquid impervious backsheet, have a body facing surfaceand a garment facing surface. As used herein, “body-facing surface”means that surface of the article or component which is intended to bedisposed toward or placed adjacent to the body of the wearer duringordinary use, while the “garment facing surface” is on the oppositeside, and is intended to be disposed to face away from the wearer's bodyduring ordinary use. The garment facing surface may be arranged to facetoward or placed adjacent to the wearer's undergarments when theabsorbent article is worn. In general the topsheet is operativelypermeable to the liquids that are intended to be held or stored by theabsorbent article, and the backsheet may be substantially impermeable orotherwise operatively impermeable to the intended liquids. The absorbentarticle may also include components such as liquid wicking layers,liquid distribution layers, barrier layers, and the like, as well ascombinations thereof.

The term ‘color’ as referred to herein includes any primary color, forexample, white, black, red, blue, violet, orange, yellow, green, andindigo as well as any declination thereof or mixture thereof. The term‘non-color’ or ‘non-colored’ refers to the color white which is furtherdefined as those colors having an L* value of at least 80, an a* valueequal to 0±2, and a b* value equal to 0±2.

One embodiment of the method is illustrated in FIG. 1. FIG. 1 shows aschematic representation of a converting line 100 according to themethod of the present invention, wherein a first substrate 101 issupplied to a contact printing station 103 within the converting line100. The contact printing station 103 prints at least one first coloredregion on the first substrate 101. A second substrate 141 is alsosupplied to a non-contact printing station 143 within the convertingline 100. The non-contact printing station 143 prints at least onesecond colored region on the second substrate 141. The first substrate101 and second substrate 141 may be supplied to the converting line 100concurrently.

With reference to FIG. 1 the method of the present invention can have amachine-direction (MD) which extends longitudinally, and a lateralcross-direction (CD) which extends transversely. The machine-directionis the direction along which a particular substrate is transported alongand through a particular position of the converting line. Thecross-direction lies generally within the plane of the substrate beingtransported through the converting line, and is aligned perpendicular tothe machine-direction.

In one embodiment, the contact printing station 103 for printing a firstcolored region on a first substrate can comprise a flexographic printingprocess 105, as shown in FIG. 2. A flexographic printing process 105 canuse any known flexographic printing apparatus and equipment, includingprocessing means known in the art. As shown, ink 107 is supplied in achamber 109 comprising a doctor blade, and which is in operativerelationship with an anilox roller 111 to which ink 107 from the chamber109 is transferred in a uniform manner as the anilox roller 111 rotatesin the direction indicated. The anilox roller 111 is in operativerelationship with a plate roller 113 such that at a transfer nip 115,ink 107 is transferred from the anilox roller 111 to the plate roller113. The plate roller 113 picks up ink 107 from the anilox roller 111 ina pattern corresponding to the first colored region printed on a firstsubstrate 101. The first substrate 101 on which the first colored regionwill be printed, such as a web for a topsheet of an absorbent article,such as a feminine sanitary napkin, is fed onto the central impressiondrum 117 (in any conventional manner), which is rotating in thedirection shown in FIG. 2.

As the first substrate 101 enters the printing nip 119 formed by theoperational relationship of the surfaces of the plate roller 113 and thecentral impression roller 117, the ink 107 on the surface of the plateroller 113 makes contact with, and is transferred to, the firstsubstrate 101.

Alternatives to the described flexographic printing process can also beused in the contact printing station of the present invention. Forexample, in certain embodiments, the contact printing station maycomprise a gravure printing process 131 as illustrated in FIG. 3. In thegravure process 131, a first substrate 101 is passed between a rubberimpression roller 132 and a gravure cylinder 133. The surface of thegravure cylinder 133 contains a large number of cells 134, which aredesigned to receive, hold, and transfer ink to the first substrate 101.Ink 135 is applied to the surface of the gravure cylinder 133 downstreamof a nip 137 and is removed from the land areas of the gravure cylinder133 with a doctor blade 138. As the first substrate 101 enters the nip137, it is pressed against the gravure cylinder 133 by the rubberimpression roller 132, thereby permitting the Ink 135 to transfer fromthe gravure cylinder cells 134 and be deposited on the surface of thefirst substrate 101 in small colored or brightened areas 139corresponding to the individual gravure cylinder cells 134.

As shown in FIG. 1, in the method of the present invention theconverting line 100 also comprises a non-contact printing station 143.The non-contact printing station 143 may use a non-contact process toprint at least one second colored region on a second substrate. In oneembodiment the non-contact printing station 143 may include an inkjetprocess. In this embodiment the non-contact printing station 143includes an inkjet printing station capable of printing a colored regionon a second substrate 141, such as a nonwoven or cellulose based web foruse as a secondary topsheet. The second substrate 141 can be provided tothe non-contact printing station 143 by any suitable means; for exampleas shown in FIG. 1, through the use of a first metering device 145 (forexample an omega roll or an s-wrap device), a series of idle rollers 147and 149, and a second metering device 151 (for example a vacuumconveyor). Both the metering devices 145 and 151 create a desiredtension in the second substrate 141 and move the second substrate 141 ina machine direction MD at a desired linear velocity V, which can be ashigh as about 6 meters/second or even greater. However, the presentinvention is applicable at any other linear velocity V of the secondsubstrate, for example, at least 5 meters/second, at least 4meters/second, at least 3 meters/second, at least 2 meters/second, andlower (which occurs during a startup of the converting line when theconverting line speed, including the linear velocity V of the secondsubstrate 141, is gradually increasing from a zero to a desiredproduction speed).

As shown in FIG. 1, the inkjet printing station 143 in certainembodiments may include a dual-head arrangement comprising a firstinkjet print head 153 and a second inkjet print head 155, disposed at aspatial distance 157 extending in the machine direction MD. However, itshould be noted that the first and the second print heads 153, 155 couldbe disposed from each other at any desired spatial distance. In certainembodiments the first inkjet print head 153 and second inkjet print head155 can be oriented in a side-by-side manner in a cross-direction acrossthe second substrate. This side-by-side orientation increases thewidthwise coverage of the inkjet print heads 153, 155.

The first and the second print heads 153 and 155 can be any type that issuitable to print a colored region, and may be disposed at a certainsuitable distance from the second substrate 141. In certain embodimentsthe distance may be form about 0.5 mm to about 3 mm, and in certainother embodiments from about 1 mm to about 2 mm. In certain embodiments,the inkjet printing station may comprise one or more digital printers,such as a continuous binary array allowing for a greater ink dropvelocity than other inkjet printers, allowing for a wider gap betweenthe print head and web to provide a quality image.

The print heads 153 and 155 can be supplied with ink from a common inksource; although in certain embodiments, separate ink sources can bealso utilized.

Each of the print heads 153 and 155 includes a multiplicity of jetsdispensing a multiplicity of substantially uniform ink dots. In oneembodiment of the present invention, each of the print heads 153 and 155can include 256 jets, forming a linear configuration in thecross-direction of about 2 inches long (about 50.8 mm). Therefore, eachof the print heads 153 and 155 can print an ink image containing 256 inkdots extending linearly about 50.8 mm across the second substrate 141.This arrangement is sufficient for printing any image of up to about50.8 mm wide, as measured in the cross-direction of the second substrate141. However, any number of jets per a print head can be provided toprint a desired width W of a colored region, which in certainembodiments, for absorbent articles produced in the process of thepresent invention can vary from about 5 mm to about 185 mm, in certainother embodiments from about 20 mm to about 105 mm.

With respect to the print heads having 256 jets, such print heads areavailable from Videojet Technologies, Inc., (Wood Dale, Ill.). Theprinting station 143 can be a part of an inkjet printing system that isalso available from Videojet Technologies, Inc., as the BX6000 seriesinkjet print system including an ink source and a controller forproviding ink and controlling jets forming individual ink droplets.

In the BX6000 series inkjet print system a continuous binary array canbe used, wherein the ink droplets are dispensed from all of the jets ofthe print heads 153 and 155 continuously, but only certain ink dropletsare allowed to reach the second substrate 141 at desired locations toform a printed image. The other ink droplets can be prevented fromreaching the second substrate 141 by deflecting the ink droplets into arecycling flow for a continuous re-use. The operation of the individualink jets of each print head can be controlled by a controller includedin the BX6000 series system.

In certain embodiments, in place of a continuous type of the inkjetprinting system the inkjet printing system can be an on-demand typeinkjet printing system (such as thermal ink jet or Peizo Drop onDemand), wherein ink typically is not recycled and ink droplets areformed on a demand basis and in a desired order to print a coloredregion.

Referring again to FIG. 1, each of the first and the second print heads153 and 155 is capable of printing colored regions separately from eachother. For example, in certain embodiments when the first print head 153is in a print mode, the second print head 155 can be in a standby oridle mode (is not printing an image on the second substrate 141).Conversely, when the first print head 153 is in a standby mode, thesecond print head 155 can be in a print mode, printing an image. Asdescribed above, in both modes of operation, the print mode and thestandby mode, the droplet formation by each of the 256 jets of each ofthe print heads 153 and 155 occurs continuously; however, in the standbymode, all of the dispensed droplets are deflected and recycled into arecycled ink flow, but in the print mode the un-deflected droplets aredeposited on the second substrate 141 and the deflected droplets arerecycled into the recycle ink flow. In certain other embodiments, thefirst print head 153 and second print head 155 can print colored regionsat the same time to print two colors. In another embodiment, the firstprint head 153 and second print head 155 can be offset in the CD toincrease the CD resolution, for example from 128 dpi to 256 dpi. A stillfurther embodiment the first print head 153 and second print head 155can be used to print the same colored region twice to increase colorintensity.

Referring again to FIG. 1, after the inkjet printing, the secondsubstrate 141 travels to a cut and placement device 159, capable ofsevering the second substrate 141 into individual sheets comprising, inthis embodiment the secondary topsheet 41, and then placing thesecondary topsheets 41 at a desired pitch interval P onto a topsheet web101 produced from the first substrate moving in a machine direction MDat a desired velocity. The topsheet web 101 can be provided and meteredat a desired velocity by any suitable means known to one skilled in theart. Then, an absorbent core web 160 (which can be also provided andmetered by any suitable means) is cut into individual absorbent cores60, which are then placed onto a secondary topsheet 41, previouslydisposed on the topsheet web 101. The cutting and placing operations ofthe absorbent core 60 can be provided by a cut-and-slip or cut-and-laydevice 161 or any suitable web cutting and placing device known in theart. Further, a backsheet web 170 (which can be also provided andmetered by any suitable means) is deposited onto the absorbent cores 60to provide a sandwiched-type web 175, which is subsequently bondedtogether and cut into individual absorbent articles 200. The bonding,cutting, and placing operations of the sandwiched-type web 175 can alsobe provided by any suitable means known in the art, for example, by afinal knife 176. A variety of suitable securing mechanisms or systemsknown to one of skill in the art may be utilized to achieve any bonding.Examples of such securing mechanisms can include, but are not limitedto, the application of adhesives in a variety of patterns between thetwo adjoining surfaces, entangling at least some portions of oneabsorbent body component with portions of the adjacent surface ofanother component, or fusing at least portions of the adjacent surfaceof one component to portions of another component of the absorbent. Theindividual absorbent articles, which in this instance are femininesanitary napkins 200, can then be transported by any suitable means,such as a conveyor 178, to other downstream operations, such as folding,wrapping, and packing.

Referring now to FIG. 4, a top view of an absorbent article producedfrom the method of the present invention is shown, which in thisillustrated embodiment is a feminine sanitary napkin 200. The femininesanitary napkin 200 can have a substantially planar configuration and acentral region 202. The central region 202 is the in-plane center ofmass of the feminine sanitary napkin 200. The central region 202 is atthe intersection between the longitudinal centerline L and transversecenterline T. The transverse centerline T is perpendicular to thelongitudinal centerline L. The feminine sanitary napkin 200 can besymmetrical or asymmetrical about the transverse centerline T. Thefeminine sanitary napkin 200 has a body facing surface 204 comprising atopsheet 208 produced from a first substrate, an absorbent core 60, asecondary topsheet 41 produced from a second substrate positionedbetween the topsheet 208 and absorbent core 60, and a garment facingsurface 206 comprising a liquid impervious backsheet 209.

In certain embodiments the topsheet, secondary topsheet, or both may becompliant, soft feeling, and non-irritating to the wearers skin andhair. Further, the topsheet or secondary topsheet is liquid pervious,permitting liquids, such as menses or urine, to readily penetratethrough its thickness. A suitable topsheet or secondary topsheet may bemanufactured from a wide range of materials such as woven and nonwovenmaterials, for example a nonwoven web of fibers; polymeric materialssuch as apertured formed thermoplastic films, apertured plastic films,and hydroformed thermoplastic films; porous foams; reticulated foams;reticulated thermoplastic films; and thermoplastic scrims. Suitablewoven and nonwoven materials can be comprised of: natural fibers, suchas wood or cotton fibers; synthetic fibers, such as polymeric fibers—forexample polyester, polypropylene, or polyethylene fibers; or from acombination of natural and synthetic fibers. When the topsheet orsecondary topsheet comprises a nonwoven web, the web may be manufacturedby a wide number of known techniques. For example, the web may bespunbonded, carded, wet-laid, melt-blown, hydroentangled, combinationsof the above, or the like.

The backsheet is substantially impervious to liquids, such as menses orurine and may be manufactured from a thin plastic film, although otherflexible liquid impervious materials may also be used. The backsheetprevents the exudates absorbed by the absorbent core from wetting auser's bedding or clothes, for example bedsheets, pants, pajamas andundergarments. In certain embodiments, the backsheet can operativelypermit a sufficient passage of air and moisture vapor out of anabsorbent article, particularly out of the absorbent core, whileblocking the passage of bodily liquids. The backsheet may thus comprise:a woven or nonwoven material; polymeric films, such as thermoplasticfilms of polyethylene or polypropylene; or composite materials such as afilm-coated nonwoven material. In one embodiment, the backsheet can be abreathable backsheet such as that described in U.S. Pat. No. 6,623,464(Bewick-Sonntag et al.) issued 23 Sep. 2003.

As shown in FIG. 4 the backsheet 209 and the topsheet 208 are positionedadjacent the garment facing surface 206 and the body facing surface 204,respectively, of the absorbent core 60. In certain embodiments theabsorbent core can be joined with the topsheet, the backsheet, or bothby known bonding means, such as those described above or those wellknown in the art. However, in certain embodiments of the presentinvention the absorbent core is unattached to the topsheet, thebacksheet, or both.

The absorbent core 60 in FIG. 1 is generally disposed between thetopsheet 208 and the backsheet 209. The absorbent core 60 may compriseany absorbent material that is generally compressible, conformable,non-irritating to the wearer's skin, and capable of absorbing andretaining liquids such as urine and other certain body exudates, such asmenses. The absorbent core 60 may comprise a wide variety ofliquid-absorbent materials commonly used in feminine care articles andother absorbent articles, such as comminuted wood pulp, which isgenerally referred to as air felt. Examples of other suitable absorbentmaterials include creped cellulose wadding; melt blown polymers,including co-form; chemically stiffened, modified or cross-linkedcellulosic fibers; tissue, including tissue wraps and tissue laminates;absorbent foams such as foams formed from High Internal Phase Emulsions(HIPEs); absorbent sponges; superabsorbent polymers; absorbent gellingmaterials; or any other known absorbent material or combinations ofmaterials. The absorbent core may further comprise minor amounts(typically less than 10%) of non-liquid absorbent materials, such asadhesives, waxes, oils and the like. Examples of absorbent structuresthat may be used in the present invention are found in U.S. Pat. No.4,834,735 (Alemany et al.) issued 30 May 1989; U.S. Pat. No. 5,625,222(DesMarais et al.)22 Jul. 1997.

The absorbent core may also include one or more superabsorbentmaterials. Superabsorbent materials suitable for use in the presentinvention are known to those skilled in the art, and may be in anyoperative form, such as particulate form. The superabsorbent materialcan be a water-swellable, generally water-insoluble, hydrogel-formingpolymeric absorbent material, which is capable of absorbing at leastabout 20, in certain embodiments about 30, and in additional embodimentsabout 60 times or more its weight in physiological saline (for example0.9 wt % NaCl). The hydrogel-forming polymeric absorbent material may beformed from organic hydrogel-forming polymeric material, which mayinclude natural material such as agar, pectin, and guar gum; modifiednatural materials such as carboxymethyl cellulose, carboxyethylcellulose, and hydroxypropyl cellulose; and synthetic hydrogel-formingpolymers. Synthetic hydrogel-forming polymers include, for example,alkali metal salts of polyacrylic acid, polyacrylamides, polyvinylalcohol, ethylene maleic anhydride copolymers, polyvinyl ethers,polyvinyl morpholinone, polymers and copolymers of vinyl sulfonic acid,polyacrylates, polyacrylamides, polyvinyl pyridine, and the like. Othersuitable hydrogel-forming polymers include hydrolyzed acrylonitrilegrafted starch, acrylic acid grafted starch, and isobutylene maleicanhydride copolymers and mixtures thereof. The hydrogel-forming polymersare preferably lightly crosslinked to render the material substantiallywater insoluble. Crosslinking may, for example, be by irradiation orcovalent, ionic, Van der Waals, or hydrogen bonding. Suitable materialsare available from various commercial vendors, such as the Dow ChemicalCompany and Stockhausen, Inc. The superabsorbent material may beincluded in an appointed storage or retention portion of the absorbentarticle, and may optionally be employed in other components or portionsof the absorbent article.

As shown in FIG. 4, the feminine sanitary napkin 200 can be consideredto have a viewing surface that is the body facing surface 204. Thetopsheet 208 and secondary topsheet 41 are visible (can be visuallyperceived by the observer) when the body facing surface 204 is presentedtowards an observer even though the topsheet is between the observer andthe secondary topsheet 41.

When the body facing surface 204 of the feminine sanitary napkin 200 isviewed, the feminine sanitary napkin 200 can have a background region214. The background region 214 is a region that is visuallydistinguishable from the first colored region 216 and second coloredregion 218. The background region 214 can be white or any other colorvisually distinguishable from the first colored region 216 and secondcolored region 218. Colors are believed to be visually distinguishableif there is a E between the two colors of at least about 1.

The topsheet 208 comprises the first colored region 216. The firstcolored region 216 can be the constituent color of the topsheet 208 withthe background region 214 rendered to have a color that differs from theconstituent color of the topsheet 208. The first colored region 216 canbe provided on, for instance, the body facing side of the topsheet 208or the garment facing side of the topsheet 208. Similarly, the secondarytopsheet 41 comprises the second colored region 218. The second coloredregion 218 can be the constituent color of the secondary topsheet 41with the background region 214 rendered to have a color that differsfrom the constituent color of the secondary topsheet 41. The secondcolored region 218 can be provided on, for instance, the body facingside of the secondary topsheet 41 or the garment facing side of thesecondary topsheet 41. The second colored region 218 can be coincidentwith the longitudinal centerline L. That is, a portion of the secondcolored region 218 can intersect with the longitudinal centerline L.

When the body facing surface 204 is viewed, the background region 214,first colored region 216, and second colored region 218 are viewable byan observer. The first colored region 216 and second colored region 218are visibly distinct from the background region 214 in that firstcolored region 216 and second colored region 218 each differ in color ascompared to the background region 214. The first colored region 216 andthe background region 214 can differ in color by a E, which is discussedin more detail below, of at least about 1. The first colored region 216and the background region 214 can differ in color by a E, which isdiscussed in more detail below, of at least about 3, if more visualdistinctiveness is desired.

Similarly, the second colored region 218 and the background region 214can differ in color by a E of at least about 1. The first colored region216 and the second colored region 218 can both differ in color ascompared to the background region 214 by a E of at least about 1. Thefirst colored region 216 and the second colored region 218 can be morevisually distinguishable if there is a E between the two colors of atleast about 3.

As shown in FIG. 4, in certain embodiments, the first colored region 216can be laterally more extensive in a direction perpendicular to thelongitudinal centerline L than the second colored region 218.

The first colored region 216 can be designed so as to be visuallycomplementary to the second colored region 218 and be presented to theviewer over a wider/more extensive portion of the body facing surface204. It is thought that by having the first colored region 216 on adifferent layer of material than the second colored region 218 that aricher visual impression can be created on the feminine sanitary napkin200. For instance, since the first colored region 216 and second coloredregion 218 are on different layers of materials, when viewed, at leastone of the colored regions will be viewed through the layer comprisingthe other colored region. A colored region viewed through another layermaterial can have a significantly different visual impression in termsof softness/diffuseness of the image, somewhat like the differencebetween a matte finished photograph versus a gloss finished photograph.

Further, if the second colored region 218 is provided by inkjetprinting, the design of the second colored region 218 can be easilychanged so that feminine sanitary napkins 200 within a single package ordifferent packages can have different designs for the second coloredregion 218. The first colored region 216 might be provided by a contactprinting apparatus that cannot be easily altered. Thus, the firstcolored region 216 can be a constant design recognizable by consumers asbeing a product from a particular brand or of a particular quality.

A first colored region 216 that is laterally more extensive than thesecond colored region 218 can also provide the impression to the wearerthat such laterally more extensive portions of the feminine sanitarynapkin 200 are capable of acquiring and retaining fluid. For instance,if the first colored region extends across a substantial portion of thefeminine sanitary napkin 200 in the cross-direction CD, viewers of thefeminine sanitary napkin 200 may interpret the first colored region 216as providing a barrier to fluid flow beyond the first colored region 216or a boundary beyond which the user should not expect fluid to pass asthe fluid travels in the machine-direction MD of the feminine sanitarynapkin 200.

The second colored region 218 can be coincident with the central region202. The central region 202, being the in-plane center of mass of thefeminine sanitary napkin 200, might be associated by the user as beingthe location of the feminine sanitary napkin 200 that should be proximalher vaginal opening or urethra. Designs in which the second coloredregion 218 is symmetric about the longitudinal centerline may providefor a more pleasing impression of the feminine sanitary napkin 200 thandesigns in which the second colored region 218 is not symmetric withrespect to the longitudinal centerline L.

As shown in FIG. 4, the second colored region 218 and first coloredregion 216 can be spaced apart from one another along the longitudinalcenterline. By spacing apart the first colored region 216 and secondcolored region 218, it is believed that improper phasing of the topsheet208 and secondary topsheet 41 that might occur when the two substratesare brought together during manufacture might not be so apparent to theuser because it might be difficult to perceive relatively smalldifferences from one pad to another pad of a gap between the firstcolored region 216 and second colored region 218. The first coloredregion 216 and second colored region 218 can be separated from oneanother by the background region 214.

As shown in FIG. 4, the feminine sanitary napkin 200 has a periphery220. The background region 214 can be between the first colored region218 and the periphery 220. Such an arrangement is thought to provide foran improved visual impression in that the periphery 220 has a clean linethat is not interrupted by colored regions of the feminine sanitarynapkin 200. For the same reason, the first colored region 216 and secondcolored region 218 can be substantially surrounded by the backgroundregion 214. For instance, less than 25% of the periphery 220 can beinterrupted by the second colored region 218 or first colored region 216or the combination of the first colored region 216 and second coloredregion 218. The second colored region 218 can be surrounded by thebackground region 214.

The second colored region 218, as shown in FIG. 4, can be asubstantially elongated shape. Without being bound by theory, it isbelieved that substantially elongated shapes that are aligned with or onthe longitudinal centerline L may make the feminine sanitary napkin 200look as if the feminine sanitary napkin 200 is slim as compared to afeminine sanitary napkin devoid of such an elongated shape. A user mightassociate such an impression with a belief that the apparently narrowfeminine sanitary napkin 200 will fit comfortably in the crotch of theirpanty. The second colored region 218, in certain embodiments can have awidth less than about 50% of the maximum distance between portions ofthe periphery 220 coincident with the transverse centerline T. Ovals andgenerally rectangular shaped shapes are examples of substantiallyelongated shapes. To provide for more visually coherent designs, thefirst colored region 216 and second colored region 218 can be within aCIELab color space volume of less than about 200. CIELab color spacevolume is discussed in more detail below. With such an approach, thecolors of the first colored region 216 and second colored region 218 donot differ substantially to the eye of most viewers and viewers mightperceive the colors to be the same or shades or subtle variations of thesame color. Subtle variations in color are thought to be pleasing to theeye, much like sample paint chips having slightly varying colors foundin home decoration stores that can be pleasurable and interesting toview. If less distinctiveness between the first colored region 216 andsecond colored region 218 is desired, the first colored region 216 andsecond colored region 218 can be within a CIELab color space volume ofless than about 50.

The first colored region 216 can be substantially arcuate shaped.Arcuate shaped first colored regions 216 are thought to be perceived byusers as barriers to flow of liquid in the absorbent article or asproviding an indication to a user that they may not want fluid to passbeyond such a colored region or that once such fluid flow has occurredthey may want to be prepared to wear a fresh product in the near future.

Arcuate shapes include, but are not limited to, shapes generallycorresponding to those found on common keyboards including the greaterthan symbol, parenthesis, circumflex (also referred to as the caretsymbol), and bracket as well as generally c-shaped shapes, and slightmodifications of any of these previously mentioned shapes. Arcuateshapes, as defined herein, can be generally curved like a letter C orcan be more angular such as the symbol <. Thus, arcuate shapes do notnecessarily have any particular curvature.

A cross section of the feminine sanitary napkin 200 illustrated in FIG.4 is shown in FIG. 5. Each component of the feminine sanitary napkin 200can be considered to have a body facing side 215 and a garment facingside 217. The body facing side 215 being oriented towards the user'sbody when the absorbent article is in-use and the garment facing side217 opposing the body facing side 215.

FIG. 6 is a schematic of a secondary topsheet 41 of a feminine sanitarynapkin having a second colored region 218. FIG. 7 is a schematic of atopsheet 208 of a feminine sanitary napkin having a first colored region216. The secondary topsheet 41 illustrated in FIG. 6 can be registeredwith the topsheet 208 illustrated in FIG. 7 to create a femininesanitary napkin 200 having a visual impression similar to thatillustrated in FIG. 4.

The color of the first colored region 216 and second colored region 218and background region 214 are measured by the reflectancespectrophotometer according to the colors L*, a*, and b* values. The L*,a*, and b* values are measured from the body facing surface 204 of thefeminine sanitary napkin 200 inboard of the periphery 220 of thefeminine sanitary napkin 200. The difference in color is calculatedusing the L*, a*, and b* values by the formulaΔE=[(L*_(X•)−L*_(Y))²+(a*_(X•)−a*_(Y))²+(b*_(X)−b*_(Y))²]^(1/2). Herein,the ‘X’ in the equation may represent the first colored region 216, thesecond colored region 218, or the background region 214 and ‘Y’ mayrepresent the color of another region against which the color of suchregion is compared. X and Y should not be the same two points ofmeasurement at the same time. In other words, for any particularcomparison of the difference in color, the location of X the location ofY.

Where more than two colors are used, the ‘X’ and ‘Y’ values alternatelyinclude points of measurement in them also. The key to the ΔEcalculation herein is that the ‘X’ and ‘Y’ values should not stem fromthe same measured point on the viewing surface. In those instances wherethere is effectively no background region 214 within the confines of themeasurement area, the ‘X’ values should flow from a point different inspatial relationship to the ‘Y’ values, but within the confines of theabsorbent core periphery.

Reflectance color is measured using the Hunter Lab LabScan XEreflectance spectrophotometer obtained from Hunter Associates Laboratoryof Reston, Va. A feminine sanitary napkin 200 is tested at an ambienttemperature between 65° F. and 75° F. and a relative humidity between50% and 80%.

The spectrophotometer is set to the CIELab color scale and with a D65illumination. The Observer is set at 10° and the Mode is set at 45/0°.Area View is set to 0.125″ and Port Size is set to 0.20″ for films. Thespectrophotometer is calibrated prior to sample analysis utilizing theblack glass and white reference tiles supplied from the vendor with theinstrument. Calibration is done according to the manufacturer'sinstructions as set forth in LabScan XE User's Manual, Manual Version1.1, August 2001, A60-1010-862. If cleaning is required of the referencetiles or samples, only tissues that do not contain embossing, lotion, orbrighteners should be used (e.g., PUFFS tissue). Any sample point on theabsorbent article containing the imparted color to be analyzed can beselected.

The feminine sanitary napkin 200 is placed over the sample port of thespectrophotometer with a white clamp disk placed behind the femininesanitary napkin 200. The feminine sanitary napkin 200 is to be in asubstantially flat condition and free of wrinkles.

The feminine sanitary napkin 200 is removed and repositioned so that aminimum of six readings of color of the body facing surface 204 areconducted. If possible (e.g., the size of the imparted color on theelement in question does not limit the ability to have six discretelydifferent, non-overlapping sample points), each of the readings is to beperformed at a substantially different region on the externally visiblesurface so that no two sample points overlap. If the size of theimparted colored region requires overlapping of sample points, only sixsamples should be taken with the sample points selected to minimizeoverlap between any two sample points. The readings are averaged toyield the reported L*, a*, and b* values for a specified color on anexternally visible surface of an element.

In calculating the CIELab color space volume, V, maximum and minimum L*,a*, and b* values reported are determined for a particular set ofregions to be measured. The maximum and minimum L*, a*, and b* valuesreported are used to calculate the CIELab color space volume, V,according to the following formula:

$V = {\frac{4}{3}{{\frac{\Delta\; L^{*}}{2}{\frac{\Delta\; a^{*}}{2}}\frac{\Delta\; b^{*}}{2}}}}$

Within the above formula, ΔL* is the difference in L* values between thetwo colored regions being compared and is calculated by:ΔL*=L*_(X)−L*_(Y). The Δa* is the difference in a* values between thetwo colored regions being compared and is calculated by:Δa*=a*_(X)−a*_(Y). The Δb* is the difference in b* values between thetwo colored regions being compared and is calculated by:Δb*=b*_(X)−b*_(Y). The CIELab color space volume can result in a solidsubstantially ellipsoidal in shape. If ΔL*, Δa*, and Δb* are equal, thesolid will be spherical. As used herein, a “solid” refers to themathematical concept of a three-dimensional figure having length,breadth, and height (or depth). An ellipsoidal volume is preferred tocalculate volume because an ellipsoid generally requires the dimensionaldifferences of ΔL*, Δa*, and Δb* to be relatively more uniform thanother solids. Furthermore, it is believed that ellipsoidal volumes aremore visually acceptable (less detectable color mismatch by humanperception) than spherical volumes.

In some embodiments, the imparted colors of at least two externallyvisible surfaces of discrete elements will occupy a CIELab color spacevolume of less than about 200. The externally visible surfaces areanalyzed according to the Test Method described below. Upon analysis,the inherent color of an element comprising an externally visiblesurface will yield L*, a*, and b* coordinates. The CIELab color spacevolume is then calculated using the formula presented above. Theresulting volume can be less than about 200. The resulting volume can beless than about 50.

It should be recognized that the imparted colors of more than twodiscrete colored regions having a visible surface may occupy theaforementioned CIELab color space volumes. In calculating the CIELabcolor space volume for more than two elements, the CIELab color spacevolume is calculated using the maximum and minimum L*, a*, and b* from aset of elements. The maximum color values and minimum color values areused to calculate V according to the formula presented above.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of producing a multi-layered absorbentarticle having two or more colored regions, the method comprising thesteps of: a. providing an absorbent article converting line; b.supplying a first substrate to the converting line, wherein the firstsubstrate comprises polymer film; c. printing a first colored region tothe first substrate using contact printing at a contact printingstation; d. supplying a second a second substrate to the convertingline, wherein the second substrate comprises fibers; e. printing asecond colored region to the second substrate using non-contact printingat a non-contact printing station; wherein the first colored region andthe second colored region do not overlap with one another; and fcombining the first substrate having a first colored region with thesecond substrate having a second colored region to produce an absorbentarticle; wherein the first colored region is printed to a surface of thefirst substrate that faces the second substrate and the second coloredregion is printed to a surface of the second substrate that faces thefirst substrate, and wherein the absorbent article is at least one ofsanitary napkins, pantiliners, tampons, interlabial devices, infantdiapers, children's training pants, adult incontinence products, orabsorbent wipes.
 2. The method of claim 1, wherein the second substrateis an airlaid cellulosic mat.
 3. The method of claim 1, wherein thefirst substrate is combined with the second substrate via a thirdintermediate layer of material.
 4. The method of claim 1, wherein thecontact printing is done using a flexographic printing process.
 5. Themethod of claim 1, wherein the non-contact printing is done using an inkjet continuous binary array.